By:

M. Asjad Aamir (2016-ME-10)

Umar Imtiaz (2016-ME-11)
Naeemullah (2016-ME-12)
 Six Sigma

Business
Strategy

Reduce Reduce Process Decrease

Production Cost Variation nonconformities
 Define

Control Measure

Improve Analyze
Problem Identification
Process Capability was reported 0.29
Controlled by different
parameters of grinding
process

Runout of shaft
identified as CTQ SPC Committee
characteristic
Team

Engineering unit
 Project Charter

Leader
Composition of
(Engineering
team
Manager)

Production and
2 Quality Control 3 Production Line
Quality Assurance
Engineers operators
Supervisors

Project Scheduling, scope,

resources, anticipated results
 Grinding

Supplier Input Process Output Customer

SIPOC Drawing and product

specifications Checking
Lubricant
Equipment Defects
Electricity
Setting process
parameters
Machine operator
Mega Motors
Machine
Features SAIPA
accessories Start the
Work instructions machine
Quality Control
Documents of
equipment In process the first off
Quality control controls
plan
Dial Bore
Gauge

Runout of shaft should be less than

0.0015mm
 Validation of
Examine Data entry
data accuracy
Two Gathering of
Selection of measurement data(60
suitable gauge experts, Ten observations
components over 8 weeks)

20% variation Examination of

Measurement in data on
of Data measurement minitab
system software
Cause Effect Diagram
Validation Plan

Causes Validation
Low precision of micrometer Calibration

Low precision of operator Evaluation

Not optimum machine parameters Experimental Design methods

Improper Feed and feed rate Process audit

Machine adjustment not done Standard operating procedures

properly
Low machine precision R&D

Using live or dead center Experimental Design methods

Validation Plan

Validate root cause Solution

Improper feed and speed rate Adjustment procedure implementation

CP machine adjustment not done properly Shaft adjustment with MAE machine

Drive changing This is introduced as a parameter to be

checked in machine preventive maintenance
checklist
Using dead center or live center Introduced dead center through DOE

Stopping & restart of machine for various Introduced operator before restarting of the
machine
Validation Plan
Validation Plan
Validation Plan

identifying improvement
stakeholders

communicating the
proposed solution and
benefits

MANAGE CHANGE learning organization

training and development

of knowledgeable staff

celebrating the success

Comparisons of results before and after the project

Before After

DPMO 725747 66807

First Yield % 27.4 93.3

Grinding process monitoring
 Defects reduction
 Reference paper for other industries
 Cost saving
 Increase in products
 Quality and customer Satisfaction
 Root cause of
problem

Lesson
Accurate learned Reduce
data
collection in quality cost
project

Use of
change
management
approach
Any
Question?
20